Hi I’m Gabe, and I have a rust problem.

TooLShack May 31st, 2006 Link

Who says the MINI isn’t like the Mini of old.

vin. May 31st, 2006 Link

Das neue MINI ist zu seinen englischen Wurzeln zutreffend!

All kidding aside, I’m checking my car over closely tomorrow morning.

Two questions:

1. Any rust problem areas besides the door sills?

2. Has there been any official MINIUSA statement about all of this?

Gabe Jun 1st, 2006 Link

1.Any rust problem areas besides the door sills?

No.

2.Has there been any official MINIUSA statement about all of this?

No.

Edge Jun 1st, 2006 Link

Gabe…

I think it’s time you got the new illuminated JCW door sills… you KNOW you want them. ;)

Edge Jun 1st, 2006 Link

Oh, I’m sorry… “entry strips”… JCW renamed them. Stupid… but I do love my IES!

chrizz Jun 1st, 2006 Link

The rust comes from the inside inmoulded iron of the actual rubber doorsill that should keep the part in shape…
It’s pretty much just sheet metal inside the rubber that kinda “transpires” the rust onto the car body.

Although I have to admit that the rust next to the b-pillar is just poor workmanship.

Christian

Greg W Jun 1st, 2006 Link

I heard about a couple of cases of surface rust in the hatch door hinge area where not enough paint was applied.

mdsbrain Jun 1st, 2006 Link

Gabe the spot of rust you show on your car is the same as on my 12month old MCS as well. But its only on one side of my car.

Charlie Jun 1st, 2006 Link

Gabe,
Is there any correlation between parking your car outside versus in a garage as far as rust formation is concerned?

Gabe Jun 1st, 2006 Link

Is there any correlation between parking your car outside versus in a garage as far as rust formation is concerned?

Not sure. I can tell you my car is parked in a garage almost exclusively though.

jdmarino Jun 1st, 2006 Link

Are these cars shipped topside?

I wonder if salt spray on the week-long voyage accounts for the ubiquity of the problem, even on garaged cars. A little salty water that is never flushed away can do a lot of rusting.

CarNut Jun 1st, 2006 Link

Playing devil’s advocate here, the rust warranty specifically states that it covers “perforation” due to rust. None of the pics I’ve seen fall into this category. It will be interesting to see how/if MINI responds. This obviously shouldn’t be happening, but taking the rust warranty wording literally, I believe MINI could claim it’s not covered. Anybody have theirs fixed yet by the dealer under warranty?

Mike Jun 1st, 2006 Link

CarNut is absolutely correct in the perforation argument that I am sure MINI will make. I thought the rust was getting its start from the unpainted rectangular area on the older MINI’s. It is disturbing to hear that rust is forming on fully painted and treated metal, as Gabe describes. I think the theory of the weatherstripping sealing in moisture is a good one. The bad news is that when I was examining this area on the 06’s, I noticed that the weatherstripping had been ‘improved’-it was thicker and beefier than my 02. It may be that this design actually seals more moisture in that area and predisposes to rust formation. I think I only saw the one breathing hole in the weatherstripping; same as my 02. Not enough, obviously.
I don’t think MINI will cover this at all until/unless the rust perforates through the metal before the rust warranty expires. I hope I am proved wrong.

dickdavid Jun 1st, 2006 Link

At least we are aware of the problem.

Are there any suggestions as to how to prevent this? I can’t see myself removing the rubber seal to dry it every time it rains or when I wash my car.

Mike Jun 1st, 2006 Link

I don’t think even the most obsessed MINI owners (myself included) would be up for that task. I wouldn’t recommend changing anything until MINI comes out with its official decision, but I think increasing the air access via more breathing holes might be one approach to consider. Obviously, its going to take a lot more than touch up paint to address this serious design flaw.

Gabe Jun 1st, 2006 Link

Are there any suggestions as to how to prevent this? I can’t see myself removing the rubber seal to dry it every time it rains or when I wash my car.

I see no way to do this. It was still moist from washing the car ten days ago. When I took off the strips initially I wiped it all down hoping to dry it out. After checking a few hours later everythng was wet again (not just moist - wet). In my very amateur opinion, the rubber seals are holding in moisture at too high a level.

dr Jun 1st, 2006 Link

Is there ANYONE who does NOT have rust in this area?

The Seeker Jun 1st, 2006 Link

Checked my 2002 MCS JCW and 2005 MC; moisture, no rust. However, when my 2002 was delivered, I noticed 3 threaded holes in the undercarriage that I assumed were used for tie down on the way over. Went in and wiped away surface rust and painted them balck. Ditto the 2005. They’re in front, in the crossmember(?).

ScottinBend Jun 1st, 2006 Link

Anyone know if this is associated more with cars that get a power wash vs a hand wash? Seems that the water needs to be forced up into the weatherstripping some way.

dickdavid Jun 1st, 2006 Link

I see no way to do this. It was still moist from washing the car ten days ago. When I took off the strips initially I wiped it all down hoping to dry it out. After checking a few hours later everythng was wet again (not just moist - wet). In my very amateur opinion, the rubber seals are holding in moisture at too high a level.

I just went to check mine. I washed it several days ago and it hasn’t rained. When I lifted the seals, a large amount of water was still there.

I’ve dried out the metal as well as the seal and I’m letting it air out for a little bit. Has anybody checked the boot seal?

dickdavid Jun 1st, 2006 Link

Anyone know if this is associated more with cars that get a power wash vs a hand wash? Seems that the water needs to be forced up into the weatherstripping some way.

The last time I did it was by hand, but I have done the power wash before. It shouldn’t matter. IMO those seals should be vented enough to let the moisture dry.

DanC Jun 1st, 2006 Link

I found mosture under the door seal too, but no rust thankfully. Hope they revise the seal to let the water out, rather than trap it. I guess they didn’t take into account the capillary action

Mike Jun 1st, 2006 Link

I wash my car often, and its always by hand in my shady driveway. No power washer gets close to my MINI. I even leave doors and hatch open afterwards to dry, after toweling the door sills. But I must confess-I never removed the weatherstripping and dried the area underneath it after each wash. If there is anybody out there who has, I suggest you see a doctor for your SOMS - severe obsessional MINI sickness ;)

danny Jun 1st, 2006 Link

Will there be any rust on the 2006 Mini Cooper…? Otherwise I’m not buying a Cooper… Just one-year?

Dave Jun 1st, 2006 Link

Will there be any rust on the 2006 Mini Cooper…? Otherwise I’m not buying a Cooper… Just one-year?

No rust on my 2006 MC (purchased in November). I checked it last night after reading Gabe’s account above. No moisture either, but I do near daily “quick detailing” and only occasionally actually wash my car.

vin. Jun 1st, 2006 Link

Checked this morning on my ‘04 MCS (1/04 build)–definitely wet under the seals (the car did sit outside during a rainstorm overnight), but no rust as of yet.

Nathaniel Salzman Jun 1st, 2006 Link

Playing devil’s advocate here, the rust warranty specifically states that it covers “perforation” due to rust

If I remember correctly, MINI did a pretty good job of fixing the last widespread rust-related problem to come up, i/e the down-to-bare-metal bonnet rub due to bad weather stripping trapping dirt in that location. MINI took care of it pretty much straight away and there wasn’t any rust at all on most of those cases - just bare metal. So I expect that especially for a problem this wide spread, a service bulletin will go out and they’ll take care of it - be it patches, or improvements to the weather stripping, or whatever. Squashing a potential MINI “rust bucket” reputation will be worth any amount of money they spend on fixing door cills.

drew Jun 1st, 2006 Link

well put nathaniel. they’ll see to it - and fast!

Bob Jun 1st, 2006 Link

I’ve got to agree with Nathaniel on this one. What has MINI ignored prior to this that would lead most of you to believe they’ll just say, “too bad, it’s not perforated”?

I’ve worked for a dealer since launch and I’d say they’ve been pretty good at addressing common issues up to this point.

Am I forgetting something?

Brian Jun 1st, 2006 Link

Would like to check for rest on my ‘05 MC, but weather stripping seems very secure. How do you actually lift or remove it to check? and replace? Thanks.

Ralph Jun 1st, 2006 Link

Since so many have lifted/removed the door seal to check for rust my questions are - 1. what’s the best way to lift up the seal to check without damaging the seal, and 2. what’s the best way to put the seal back for a proper fit (orginal fit)?

Seals and things once removed usually don’t fit/go back the same way as orginal. I’ve tried to lift up the seal (half heartily) but it seems like it takes some force.

Gabe, since you seem to work on your Mini quiet a bit any hints? Thanks.

agranger Jun 1st, 2006 Link

From page 30 of “MINI Cooper and MINI Cooper S Service & Warranty Information 2006″ which came with my ‘06 MCS in December of ‘05:

Required Maintenance:
In order to keep this warranty in effect, the vehicle must be inspected at every MINI Inspection I and II or at least every two years.

The Inspection / Maintenance consists of:

• Repairing any damages to undercoating or paint due to stone chips, gravel erosioni, scratches, or other external influences

THIS INSPECTION / MAINTENANCE IS EXCLUDED FROM THE RUST PERFORMATION LIMITED WARRANTY. ANY AREAS REQUIRING PREVENTATIVE MANITENANCE MUST BE REPAIRED, AND ARE AT THE OWNER’S EXPENSE. (Caps are original to document)

(farther down)

This warranty does not apply to the following:

a. Damage caused by negligence, improper accident damage repairs or improper use.
b. Damage attributable to failure to perform required inspections / maintenance at the specified intervals or in accordance with the MINI rust inspection / maintenance program instructions. Proof must be provided by a paid invoice or filling in the appropriate boxes in teh Service Section of this Statement.

(on page 15 of same document)

Underbody maintenance

The underbody has to be cleaned at least once a year, in spring, with plain water in order to remove mud, chemical sediments and other deposits. If those materials are not removed, corrosion (rust) will occur.

Your MINI Dealer will do this anti-corrosion service for you.

Ken (WingNut) Jun 1st, 2006 Link

I’m thinking this is just a new quirk to be attended to yearly or bi-yearly. Simply removing the seal, removing the rust, repainting it and covering back up again.

Just one of those things. Sure it sucks, especially if your MINI is only a year old… but, has to be done. Thankfully it’s in a place where you can cover up the repair and it won’t be noticable.

It could be worse, we could all find that our MINI-FINI cup holders have been replaced with the big stupid one while we slept!

:dashes from the room!:

Mike Jun 1st, 2006 Link

I hope you’re right Nathaniel, but I see the bonnet issue as much less complex. All MINI did there was to make some cheap plastic shields that protected the area, and that was done only after it was pointed out to them on this web site. I find it hard to believe that the MINI service techs who were lifting bonnets daily never noticed it. It just wasn’t pursued until there was a little stink made. There was no rust to deal with because any moisture that may have been present (unlikely in the first place due to location) would have evaporated with engine heat. Now they are looking at not only replacing or modifying the weatherstripping, but repairing the rust that has already started on many cars. That will involve a lot more than just some touch up paint. Once the body shop becomes involved, you are looking at lots of expensive labor. I would think it would be at least a two day process between the surface prep, primer application, and final paint. The fact that it is in a hidden area may work against us, actually, by allowing the body shop to cut corners on the job since it will not be in full view.

I really hope I’m wrong about this, but so far, MINI’s silence on this issue is a little disconcerting, to say the least.

MillieTheMini Jun 1st, 2006 Link

Just to let you all know,

Up here in Canada, I took my car to my MINI dealership, showed the rust spots in those areas on my ‘03 MCS to my service advisor.

I now have an appointment for next week to drop my Millie off for a couple of days, where she will be taken to a bodyshop for the affected areas to be sandblasted and repainted - under warranty, of course!

Until it’s all done next week, I won’t say it’s all taken care off. Never know if the dealership may have a last minute change of heart - but right now, it looks like I’ll be taken care of.

Make sure to always spend as much time cleaning the underside/wheelwells of your car as much as you wash the exterior. A good blast from the hose of clean water around the wheelwells, undercarriage and exhaust area makes helps removes potentially corrosive contaminants on a regular basis.You should do that everytime you wash your car.

Dave Jun 1st, 2006 Link

Probable cause of rust:

having inspected my car and I have a theory. These points on the car where there is potential for rust (I have surface rust) are probably contact points for painting using electrostatic paint processes. For some bizarre reason BMW engineers thought it would be ok to cover these post paint with clear plastic sealers (on my 03). This appears to be an inadequate method to prevent rust in an area that naturally retains moisture.

Potential solutions:
1. retrofit door strip with venting (would require MINI to issue a new part at considerable expense so substantial pressure would need to be brought to bear on MINI)
and/or
2. remove plastic “sealer” over offending areas. Remove all rust. Paint with appropriate rust inhibiting primer and top coat.

Clearly the best solution is to effect both of these solutions.

Dave Jun 1st, 2006 Link

Follow-up note

This IS a design defect. Restrictions contained within the warrantee not withstanding MINI should be held accountable for a fix.

An effective way of getting MINI to do something about this is to start filing complaints with the nhtsa

http://www-odi.nhtsa.dot.gov/cars/problems/defect/defectsearch.cfm

MillieTheMini Jun 1st, 2006 Link

Just adding my thoughts here about the fact that it’s mostly 2002 and 2003 models that showing the rust problem:

It may not be specific to those model years, just that it may take 2-3 years before those moisture-saturated areas begin to display rust. With that in mind, it could be possible that the 2004 (and some 2005) models may start displaying the same symptoms the same time next year.

Dave Jun 1st, 2006 Link

Just filed a complaint with the nhtsa - I strongly encourage others to do so.

O(=^=)OCapn Jun 1st, 2006 Link

I would say complain if nothing happens and we are forced to put pressure on MINI to fix this. It was just discovered and we need to find out what thier response is first before we grab the pitch forks.

Jim Jun 1st, 2006 Link

Has anyone noticed this problem with a convertible? Mine will be at the dealer within the month, and I’ve not seen any mention of this problem affecting the convertible.

GSKChicago Jun 1st, 2006 Link

Hey Stracco? Any thoughts on this one?

Mike Jun 1st, 2006 Link

MillieTheMini-so glad to hear your rust should be history soon. I wonder if your road salt exposure may help start the process up there compared to some of our warm weather MINI’s down here, though once rust starts, it obviously worsens with warmer temps. Kudos to your dealer for coming through. Did they mention if you were the first one to complain, or have they done this for other customers? It looks like it was cleared through MINI CA for your dealer to be reimbursed for the warranty work. It was nice to hear some good news on this thread.

Andrew Jun 1st, 2006 Link

I checked out mine last night and, while wet, thankfully all is ok - but the car is only 2 months old. It actually looks like the water is being channelled down from the bottom edge of the black plastic A pillar where it meets with the wrap around chrome strip. I say this cause my car is absolutely filthy on the bottom half due to road works and we have had rain over the last couple of days. The water that I found sitting in the weather strip was perfectly clean no grime what so ever. I don’t use a pressure cleaner to wash the car just a dribble of water (due to water restrictions currently in force) and generally the door sills are dry when I finish washing so it is unlikely to have been forced up there from the bottom edge of the door.

A redesigned weather strip that actively channels water from the windscreen towards the outside of the car, rather than underneath and along the inside of the weather strip, looks like the solution.

David Lalonde Jun 1st, 2006 Link

Millie, who is your dealer in Canada? I mentioned it to Graham at MINI Yaletown service and he had yet to hear about this issue.

Regards,
David
05 MCS BEP

Mark Jun 1st, 2006 Link

I checked my 2006 MCSC today - no rust and no sign of moisture. The car was washed very thoroughly on Monday and sat out in a good rain storm earlier this week.

Maybe something has changed for 2006 or on convertibles. Or maybe 2006 builds are just too new to see the problem.

I’m sure that MINI will get on top of this issue.

Mark S.

Pedro Jun 1st, 2006 Link

Just took delivery of 2006 MCS last week. Needless to say - this is freaking me out. Especially since there is an 8 inch area under my door that did not come painted from the factory. I know that is slightly different than the area you all are mentioning but I may have to get my dealer to put paint on there to protect the car if they are so easily rusted. Have not checked under my seal as I doubt in 1 week there is any rust there.

Gabe Jun 1st, 2006 Link

Okay I’m going go on record here - Let’s all try to be a little relaxed about this until we know more.

…off soap box.

Bob Woods Jun 1st, 2006 Link

Very disappointing. This is an expensive small car with many design oversights. I will buy the new Rabbit to replace it — cheaper and better IMO.

Karla Jun 1st, 2006 Link

OMG. A little moisture. Let’s trade for Rabbits. Let’s contact the NTSB. That square centimeter of rust will surely cause accidents.

Rust isn’t a good thing, but c’mon guys — the sky isn’t falling.

Steve J Jun 1st, 2006 Link

Well after reading this post I went to Buster to check under his weather strip and what did I find??? He has “RUST”……For back round…Buster was born at the end of July 2005, delivered end of August of 05 and has been driven for 21000 miles and in less than a year he has already developed rust under the weather stripping on the drivers side right smack dab in the middle of the sill…I will let everyone know what the dealer says on monday because Buster yet again goes in to have the window fixed for up/down for the open/close function (forget what its called)…But Buster will still enjoy the Mini vacation in St lOuis before then…

Cheers.
Steve

Al Darko Jun 2nd, 2006 Link

I guess its no longer “mass hysteria” now that it has affected you…..

Gabe Jun 2nd, 2006 Link

It is absolutely mass hysteria. Have you read some of these comments!? :-)

dr Jun 2nd, 2006 Link

The sky IS falling for MINI if this is not dealt with…..I will sell my car before this becomes a well-known issue and re-sale drops like a rock….If the reputation gets out as these being rust buckets nobody will want them!

Pedro…please post pictures of your 8 inches……….Of un-painted sill/door. perhaps this is a paint process issue

Lee L Jun 2nd, 2006 Link

Gabe, since you took teh stip off to dry it, then saw the moitsute come back, do you think it is possible that water is getting in some void and then wicking back up to the seal?

I know there have been some issues with a wet seat belt associated with a broken drip channel that goes around at thr top of the glass line. Could there be other problem as well that cause smaller leaks even when it works as designed that allow water down into teh bottom of the car?

James Jun 2nd, 2006 Link

Gabe,

Have you taken your MCS in to have service look at it yet? Did they do anything special to the rubber seal or replace it? I’m taking my ‘05 MCS in for service next week and I wanted to see how your dealer handled it.
Thanks.

Disco Stu Jun 2nd, 2006 Link

I don’t know about y’all, but my ’03’s hatch rubber seal is FULL of water all the time.

I can’t sit in the open hatch on the seal without my butt getting wet.

It doesn’t come off easily like the door seals - is there rust in there too????

I almost don’t want to know….

Shooler Jun 2nd, 2006 Link

Just checked my 05. Found a very small area on the drivers side, none on the passenger. I’m not to concerned at this point. I’ll let my Service Advisor know about it at my next service.

Copoly Jun 3rd, 2006 Link

Very disturbing news Gabe!
I ran home immediately to check out my April 05 built MCS. I found just a miniature amount of brownish discoloration on my pass side; just on the top of the sill flange. When I pulled the sill out, it was wet underneath; the car was last driven in rain 3 days prior to it! I have to mention that this car has been stored all winter, and there is no explanation for this at all. The problem is the sill holding too much moisture; most likely the water is coming from the top, probably around the lower part of the A-pillar, and the gravity holds it at the bottom. I don’t think that water can travel from the lower door-opening to the Sill. Although I think the door-sill (that is the rubber piece on the button of the door), is not really strong and long enough, in my opinion, to catch all the water coming in from the lower door cut line.
I should mention that I’m not too concern at the moment, because I really can’t call this brownish spot “Rust” yet, but it is a beginning in itself.

Let me mention that as Gabe mentioned, we all should be calm, this is not an un-common problem on vehicles, but I would STRONGLY urge every MINI owner to first check this flange closely for any discoloration, or rust, and then spread the word to others. The next step would be a trip to the local dealer and let them know about the problem. The sooner MINI found out about this, the cheaper would be for them to come up with some solution, and the sooner we all get a resolution on this.
Solution would be either, new sill design, or applying some sort of material on the flange itself, to prevent it from corrosion. I’m going to the dealer this Monday for some service; I’m going there with some printed out photos of your “Flickr Rust Folder” account. I will let you all know what happens.

Lets Motor!

Copoly

p.s. The terminology for this type of door sill is “Bulb-Sill”, since the cross-section looks like a “Light-Bulb”; that is the area that get compressed when you close the door, to create a tight sill. The small holes you see on rubber is for ventilation of the air from the bulb section, when you close the door, and it is not connected to the area of the sill that hugs itself on the flange.
Another note on putting the sill back to its position, you want make sure to start from the outside, and work your way toward inside, these sill have designed to hold the shape of the door opening, really tight. Also when you put the sill back, please be careful, the inner part of the sill has a metal structure, make sure you don’t damage the paint on the sill flange.

andrew Jun 3rd, 2006 Link

Just checked for this on my 04, and sure enough there was a little bit of rust starting under the seal. Thanks for the tip!

David Jun 4th, 2006 Link

This is very disappointing. No the sky isn’t falling, but I’m surprised at the lengths some people go to forgive design mistakes. This is BMW. How long have they been designing cars? Weatherstripping ventilation/rust should be a non-issue. I’m someone who is considering this car after 15 years with Acura products. My current 9 year old Integra has no rust whatsoever. This is just the sort of thing that makes me want to stay with what I know and not risk having this kind on nonsense cropping up an a PREMIUM priced car. I’ve been burned by German engineering in the past and I’m starting to get that “run away” feeling.

If I had a one year old car in the year 2006 that was rusting, I would be p*ssed!!!!! This is BS folks!

danno Jun 5th, 2006 Link

Unbelievable! Old world craftsmanship at its worst. Some things never change. Even Hyundai figured out how to keep its paper-thin sheetmetal from rusting for more than one year. BMW has a growing problem on its hands and they’d better make this right - fast. This has the potential to drop their high profit little darling into a deep and expensive hole. A rust problem on a new BMW designed car?! WOW!

The future of the MINI if BMW doesn’t fix this fast:

“Hi, I’m calling about the MINI you have for sale in the paper…is it all rusty?”

“Sorry, we can’t take a MINI trade-in. People think they rust and now we can’t give them away…”

Copoly Jun 5th, 2006 Link

Danno,

Please chill out man! This is not as big of a deal as you think, yet. I’m sure BMW is going to make us all proud at the end. We just have to keep them inform, as quickly as we can.

Cheers,

Copoly

Pedro Jun 5th, 2006 Link

While some have gone overboard on this issue without giving BMW a chance to respond, I must admit that this is in fact a big deal. Rust on a 1 year old car is a HUGE deal (totally unacceptable). Let’s not downplay the seriousness of the issue. At the same time, let’s not shout the world is ending from every corner either. Some valid points have been made, however. People considering the MINI who do their online research will find these posts and some may think twice while others will buy the car for the same reasons most of us own ours.

Let’s give BMW a chance to investigate and announce their findings/plan for correction. If we don’t hear anything within a month or so I would then suggest cranking up the heat a notch.

Liam Jun 5th, 2006 Link

I have an Australian spec 2004 MCS (April build) at this stage my car has just one tiny spot on the passenger’s side. The driver’s side is all clear. Quite a few Australian owners posting on MINI2 have the issue as well, some not so bad, others worse.

When checking my car I also had a very quick look at the rear hatch opening. I did not remove the rubber strip completely so I could see the entire hatch opening, however the areas I did see were all okay. Also of note while doing this was the fact that some sort of wax-like substance was evident between the painted metal and the rubber strip. Perhaps a substance like this on the door sills may have prevented, or at least prolonged, the rust issues there???

zipzip Jun 7th, 2006 Link

This past weekend after washing the car I pulled up the rubber door seals and found rust spots on both sides. Whipping out the warranty book and seeing the vehicle is warranted “against defects in materials or workmanship which will result in rust perforation of the vehicle body for a period of 6 years, without milage limitation” I called the dealship. They said they needed to see the car so I brought it in today. We pulled up the seals, he saw the rust spots and said that he needed to speak to the service manager. He came back saying I’d need to come back on later in the month when the regional Mini technician is there. He said this guy needs to see, and approve, any warranty claims against paint. I figured the dealership should have been able to make a determination, but I guess not. Anybody else have to go through this. Any warranty claims disapproved?

Copoly Jun 8th, 2006 Link

zipzip,

What year is your?

ZipZIp Jun 8th, 2006 Link

1. Never been in an accident, garage kept, yearly dealership inspections performed. Couldn’t believe the amount of moisture underneath the seal after just washing it. Previous posts seem to indicate dealers are agreeing it’s a warrantied fix whereas mine wants this additional Mini field rep to look at it to determine if it’s a covered fix. It’s crazy but I now know I’ll have to pull up the seal after every wash or after driving in the rain for the area to dry out to prevent future rust. Just wondering what response other owners wanting the rust repaired under warranty are getting from their dealerships. Thanks.

ZipZIp Jun 8th, 2006 Link

It didn’t post the year for some reason. It’s a 2002

Randy Jun 8th, 2006 Link

While some have gone overboard on this issue without giving BMW a chance to respond, I must admit that this is in fact a big deal. Rust on a 1 year old car is a HUGE deal (totally unacceptable). Let’s not downplay the seriousness of the issue. At the same time, let’s not shout the world is ending from every corner either. Some valid points have been made, however. People considering the MINI who do their online research will find these posts and some may think twice while others will buy the car for the same reasons most of us own ours.

Let’s give BMW a chance to investigate and announce their findings/plan for correction. If we don’t hear anything within a month or so I would then suggest cranking up the heat a notch.

Gang, if you are waiting for some announcement from BMW/MINI, you may be waiting for a long time. IMHO, the best we can hope for is a silent recall, i.e., the dealers getting the OK to repair rust on an as needed basis. Since this is not a safety issue, they aren’t going to announce this to all current owners worldwide - that’s just asking for expensive grief. Most owners have no clue about this (hidden) problem and BMW would have to be nuts to send everyone out to pull up their weatherstripping. It looks like most would find some degree of rust. This will be a fix on demand problem. (But, there is probably a team of engineers scrambling to fix this for ‘07 and beyond.)

Ken Jun 10th, 2006 Link

I am going to repeat a question from an earlier post, because I have not seen an answer, and I have the same question:

what’s the best way to lift up the seal to check without damaging the seal?

I have tried lifting the seal, and it won’t budge. Maybe the real question is:

Why are some folks’ seals coming up so easily?

Ken

Rich Jun 14th, 2006 Link

Hi All,

I’m in the UK and have an 05 convertible. The warranty here says 2 years for paint and 6 years for perforation by rust. That suggests the rust warranty wouldn’t apply unless it was holed. The paint warranty says “..against defects such as blistering, discoloration or staining of the visible surface of all painted body panels..” So, it seems they could argue their way out of that one too as it’s not usually visible.

Bottom line over here though is the 1979 Sale of Goods Act which says the item should be of “satisfactory quality”. This is regardless of any manufacturer warranty. It also covers things that might arise after the sale date that the purchaser could not be expected to check for at that time. On a car of this price rust would not be satisfactory imo but they still might argue it was not usually visible and make you wait to claim until it was. Problem then is that you should fix any problems as soon as they are known.

My exp is that car manu’s will shirk anything they can after they have your money so hit them with this NOW and don’t let them off ’til they commit themselves to a line of procedure you are happy with. These are expensive cars and we have a right in sales law to expect them to be better than cheaper cars. The residuals will soon dive if they become known as rust buckets and the maker does not support them. I have a rust issue with our 4 year old VW Passat at the moment. Check your household insurance to see if you have legal cover and give them a ring to see how to progress. Rich.

Adam Jun 19th, 2006 Link

I have not had time to investigate this myself so I asked Morristown Mini to do this for me when they had my car in for the four year coolant flush.

My car is a May build 2002 that has its share of woes so I am very nervous. Morristown Mini refused to check per the SA because the rep from miniusa said they could not break the rocker panels to investigate this.

Am I crazy or is this a bogus line? What has everyone else done to investigate the issue without braking the car?

Mike Oct 8th, 2006 Link

It’s been over three months since MINI learned about this issue. What’s been done to notify owners and repair their cars? The silence has been deafening. Looks like this is going to be one of those silent recall items. The vast majority of MINI owners will never find out about this issue.

Copoly Oct 15th, 2006 Link

I agree Mike. I’m planning on writting a letter to MINI and compain with pictures.

Timmee Nov 30th, 2006 Link

Any update on this issue?

brian Feb 22nd, 2007 Link

Has anyone got this issue successfully resolved via Mini USA? Mine has been “on record” for about 6 months and I’m ready to slap a coat of POR-15 on it myself unless Mini USA has an official fix.

whiteroofradio.com - The MINI Cooper Podcast » Woofcast #66 Aug 15th, 2007 Link

[...] Gabe has rust…I’m sure so does most everybody [...]

MotoringFile » Archive » White Roof Radio #247 May 25th, 2008 Link

[...] Gabe has rust…I’m sure so does most everybody [...]